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EFFECTIVE: June 28, 2022
Owner’s Manual
THEATRICAL
CHAIN HOIST
TNER
SERIES
1/2 Ton through 2 Ton Capacity
Code, Lot and Serial Number
This equipment should not be installed, operated, or maintained by any person who has not read and understood all the contents of this manual. Failure to read and comply with the contents of this manual can result in serious bodily injury or death, and/or property damage.
© HARRINGTON HOISTS, INC.
ALL RIGHTS RESERVED
Table of Contents
Section
Page Number
1.0 Important Information and Warnings ……………………………………………………………………… 4
1.1 Terms and Summary
1.2 Warning Tags and Labels
2.0 Technical Information…………………………………………………………………………….…………. 8
2.1 Specifications
2.2 Dimensions
3.0 Preoperational Procedures ………………………………………………………………………………..10
3.1 Gearbox
3.2 Chain
3.3 Mounting Location
3.4 Mounting the Hoist
3.5 Electrical Connections
3.6 Preoperational Checks and Trial Operation
4.0 Operation …………………………………………………………………………………………………... 16
4.1 Introduction
4.2 Shall’s and Shall Not’s for Operation
4.3 Hoist Controls
5.0 Inspection ………………………………………………………………………………………………….. 19
5.1 General
5.2 Inspection Classification
5.3 Frequent Inspection
5.4 Periodic Inspection
5.5 Occasionally Used Hoists
5.6 Inspection Records
5.7 Inspection Methods and Criteria
2
Section
Page Number
6.0 Maintenance & Handling …………………………………………………………………………………. 26
6.1 Lubrication – Load Chain, Hooks and Gearbox
6.2 Motor Brake
6.3 Load Chain
6.4 Friction Clutch
6.5 Storage
6.6 Outdoor Installation
7.0 Troubleshooting …………………………………………………………………………………………… 32
8.0 Warranty …………………………………………………………………………………………………… 35
9.0 Parts List …………………………………………………………………………………………………… 36
Appendix A: Wiring Diagram …………………………...………………………………………………………… 53
3
1.0 Important Information and Warnings
1.1 Terms and Summary
This manual provides important information for personnel involved with the installation, operation and maintenance of this product. Although you may be familiar with this or similar equipment, it is strongly recommended that you read this manual before installing, operating or maintaining the product.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures that can present hazardous situations. The following signal words are used to identify the degree or level of hazard seriousness.
Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury , and property damage.
Warning indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury , and property damage.
Caution indicates a potentially hazardous situation which, if not avoided, may result minor or moderate injury or property damage.
Notice is used to notify people of installation, operation, or maintenance information which is important but not directly hazard-related.
These general instructions deal with the normal installation, operation, and maintenance situations encountered with the equipment described herein. The instructions should not be interpreted to anticipate every possible contingency or to anticipate the final system, crane, or configuration that uses this equipment. For systems using the equipment covered by this manual, the supplier and owner of the system are responsible for the system’s compliance with all applicable industry standards, and with all applicable federal, state and local regulations/codes.
This manual includes instructions and parts information for a variety of hoist types. Therefore, all instructions and parts information may not apply to any one type or size of specific hoist. Disregard those portions of the instructions that do not apply.
Record your hoist’s Code, Lot and Serial Number on the front cover of this manual for identification and future reference to avoid referring to the wrong manual for information or instructions on installation, operation, inspection, maintenance, or parts.
Use only Harrington authorized replacement parts in the service and maintenance of this hoist.
4
Equipment described herein is not designed for and MUST NOT be used for lifting, supporting, or transporting people, or for lifting or supporting loads over people.
Equipment described herein should not be used in conjunction with other equipment unless necessary and/or required safety devices applicable to the system, crane, or application are installed by the system designer, system manufacturer, crane manufacturer, installer, or user.
Modifications to upgrade, rerate, or otherwise alter this equipment shall be authorized only by the original equipment manufacturer.
Equipment described herein may be used in the design and manufacture of cranes or monorails. Additional equipment or devices may be required for the crane and monorail to comply with applicable crane design and safety standards. The crane designer, crane manufacturer, or user is responsible to furnish these additional items for compliance. Refer to ANSI/ASME B30.17, “Safety Standard for Top-Running Single Girder Cranes”;
ANSI/ASME B30.2 “Safety Standard for Top-Running Double-Girder Cranes”; and ANSI/ASME B30.11 “Safety
Standard for Underhung Cranes and Monorails”.
If a below-the-hook lifting device or sling is used with a hoist, refer to ANSI/ASME B30.9, “Safety Standard for
Slings” or ANSI/ASME B30.20, “Safety Standard for Below-the-Hook Lifting Devices”.
Hoists and cranes, used to handle hot molten material may require additional equipment or devices. Refer to ANSI
Z241.2, “Safety Requirements for Melting and Pouring of Metals in the Metal Casting Industry”.
Electrical equipment described herein is designed and built in compliance with Harrington's interpretation of
ANSI/NFPA 70, “National Electrical Code”. The system designer, system manufacturer, crane designer, crane manufacturer, installer, or user is responsible to assure that the installation and associated wiring of these electrical components is in compliance with ANSI/NFPA 70, and all applicable Federal, State and Local Codes.
Failure to read and comply with any one of the limitations noted herein can result in serious bodily injury or death, and/or property damage.
5
HAZARDOUS VOLTAGES ARE PRESENT IN THE CONTROL BOX, OTHER ELECTRICAL COMPONENTS,
AND CONNECTIONS BETWEEN THESE COMPONENTS.
Before performing ANY mechanical or electrical maintenance on the equipment, de-energize (disconnect) the main switch supplying power to the equipment; as well as lock and tag the main switch in the de-energized position.
Refer to ANSI Z244.1, “Personnel Protection – Lockout/Tagout of Energy Sources”.
Only trained and competent personnel should inspect and repair this equipment.
It is the responsibility of the owner/user to install, inspect, test, maintain, and operate a hoist in accordance with
ANSI/ASME B30.16, “Safety Standard for Overhead Hoists”, OSHA Regulations and ANSI/NFPA 70, National
Electric Code. If the hoist is installed as part of a total lifting system, such as an overhead crane or monorail, it is also the responsibility of the owner/user to comply with the applicable ANSI/ASME B30 volume that addresses that type of equipment.
It is the responsibility of the owner/user to have all personnel that will install, inspect, test, maintain, and operate a hoist read the contents of this manual and applicable portions of ANSI/ASME B30.16, “Safety Standard for
Overhead Hoists”, OSHA Regulations and ANSI/NFPA 70, “National Electric Code”. If the hoist is installed as part of a total lifting system, such as an overhead crane, the applicable ANSI/ASME B30 volume that addresses that type of equipment must also be read by all personnel.
If the hoist owner/user requires additional information, or if any information in the manual is not clear, contact
Harrington or the distributor of the hoist. Do not install, inspect, test, maintain, or operate this hoist unless this information is fully understood.
A regular schedule of inspection of the hoist in accordance with the requirements of ANSI/ASME B30.16 should be established and records maintained.
TNER hoists may be supplied with an auxiliary control circuit to be used for individual control while connected to a multiple hoist control system. Always disable the multiple hoist controller when operating the hoist with local pendant control. Failure to do so will cause a potentially hazardous situation. Always use a single control source when operating the hoist.
6
1.2 Warning Tags and Labels
The warning tag illustrated below in Figure 1-1 is supplied with each hoist shipped from the factory. If the tag is not attached to your hoist or hoist’s pendant (pickle) cord, order a tag from your dealer and install it. Read and obey all warnings attached to this hoist. Tag is not shown actual size.
Front Back
Figure 1-1 Warning Tag
7
2.0 Technical Information
2.1 Specifications
2.1.1 Product Code
2.1.2 Operating Conditions and Environment
Temperature range: -4° to +104°F (-20° to +40°C)
Humidity: 85% or less
Noise Level: 85 dB or less (A scale: measured 1 meter away from electric chain hoist)
Enclosure Rating: Hoist Meets IP55, Optional Pendant (Pickle) Meets NEMA 4X
Supply Voltage: Single Speed Standard: Reconnectable 208/230 & 460V-3-60
Single Speed
Capacity
(Ton)
1/2
1
2
1
2
Hoist Duty Rating:
Intermittent Duty Rating:
Short Time Duty Rating:
Product
Code
TNER005L
TNER010L
TNER020L
TNER010S
TNER020S
ISO M3; ASME H3
25% ED
150 starts per hour
30 min.
Lifting
Speed
(ft/min)
16
8
32
16
Table 2-1 Hoist Specifications
Output
(Hp)
Motor
Current Draw
(amps)
208V or
230V
460V
Load
Chain
Wire
Diameter
(mm) x
Chain Fall
Lines
0.65 3.7 1.9 6.3 x 1
1.3 5.6 2.8
8.0 x 1
2.4 10.4 5.2
8.0 x 2
8.0 x 1
8.0 x 2
Load
Sheave
Pockets
4
Net Weight with 60 Feet of Lift
(lbs)
104
146
217
155
225
Weight for One
Addnl.
FT. of
Lift
(lbs)
0.57
0.93
1.9
0.93
1.9
8
2.2 Dimensions
Figure 2-2 Hoist Dimensions (See Table 2-3)
Table 2-2 Hook Dimension*
C = Chain Hook
B = Body Hook
Units = inch
Capacity Code Hook
005L
C
B a
1.1 b
0.7 c
0.9
010L/S
C
B
C
1.0
1.4
1.2
1.9
0.6
0.9
0.8
1.1
0.9
1.2
1.0
1.6
020L/S
B 1.6 1.0 1.3
*Refer to Section 5.7 for inspection dimensions and limits. d
0.7
0.6
0.9
0.8
1.1
1.0
Table 2-3 Hoist Dimensions
Product
Code
TNER005L
Minimum
Headroom
C
(in)
13.2
L*
(ft) a
(in)
18.7 b
(in)
14.2 d
(in)
9.6 e
(in)
9.2 g
(in)
0.9 h
(in)
3.9
TNER010L
TNER020L
16.1
22.8
16.1
22.8
2.5
20.0 15.0
10.2
8.8
9.8
11.2
1.2
1.5
1.2
1.5
4.1
TNER010S
TNER020S
*Standard length of control and power cables unless otherwise specified.
e
1.4
1.7
1.7
1.9
2.0
2.1 i
(in)
4.0
4.7 g
0.9
1.1
1.2
1.3
1.5
1.6
D
(in)
35.4
37.0
48.8
37.0
48.8
9
3.0
Preoperational Procedures
3.1 Gearbox
3.1.1 The gearbox is filled with the correct amount of grease at the time of shipment.
3.1.2 Refer to Section 6.1.3 when replacing the gear grease.
3.1.3 Gear grease for TNER is Sumiplex L-Mo No.1 (Part No. SA1BS1855). 3.2 oz. (90 grams) of grease is used to lubricate the gears.
3.2 Chain
3.2.1 The chain components include Ball Stopper, Chain Coupling, Chain Clip and Chain Container
Assembly. Never operate the hoist with incorrect, missing, or damaged chain components. Ensure that all chain components are in the correct location and properly installed as shown in Figure 3-1.
Figure 3-1 Chain Components Arrangement
3.2.2 The Ball Stopper must be installed at least 40 inches away from the no load end of the chain.
Tightening torque for the Ball Stopper Bolt is 10 N-m (7 lb-ft).
3.2.3 The Chain Coupling and the Chain Clip are installed at the no load end of the chain.
3.2.4 Canvas Chain Container - fully unfold and install it on the hoist body as shown in Figure 3-2. Be sure to mount the chain container in the orientation where the hook guard is away from the hoist body as shown in Figure 3.1. The no load end of the chain is attached to the chain container bracket by the
Chain Clip as shown in Figure 3.1. To place the chain into the chain container, feed the no load end of the chain into the container gradually. Take care to avoid twisting or tangling the chain. NEVER put all the chain into the container at once.
10
3.2.5 When running chain through the hoist without a load, check for knots in the chain prior to use. TNERs are typically chained with long lift lengths which makes knotting of the chain easier to occur and more difficult to detect. Always monitor the chain while operating the hoist to verify that there are no knots and that the chain is being fed into the hoist in-line with the outer chain guide and axis of rotation of the load sheave. Knots in the load chain may cause the paddle limit switch to operate improperly.
3.2.6
Operating this hoist without the correct Harrington chain container may create a potentially harzardous situation. To avoid this potentially hazardous situation, always operate this hoist with the correct chain container installed.
3.2.7
Each chain container indicates the maximum length of the load chain that can be stored in the container. The amount of chain the container must hold is equal to the lift on the hoist.
For 2 Ton models, twice the length of chain is needed to achieve the same lift length. DO NOT use a chain container with a storage capacity less than the lift length on the hoist, or twice the lift length for 2
Ton models. If all of the chain cannot be stored in the container, excess chain can fall from the container and cause bodily injury or death.
Body Plate Hi-Coupling Hi-Coupling
Container Hook
Attachment
Figure 3-2 Attachment of Chain Container to Hoist Body
11
3.2.8
Verify that the load chain is not twisted or tangled prior to operating the hoist.
Make sure the chain hook on 2 Ton double fall models is not capsized. See Figures 3-3 and 3-4.
Correct all chain irregularities before conducting the first hoist operation.
Figure 3-3 Twist in Load Chain – 2 Ton Double Fall Models
Figure 3-4 Capsized Hook and Chain –Double Fall Models
3.3 Mounting Location
3.3.1
Prior to mounting the hoist ensure that the suspension and the supporting structure are adequate to support the hoist and its loads. If necessary consult a professional that is qualified to evaluate the adequacy of the suspension location and its supporting structure.
3.3.2
See Section 6.6 for outdoor installation considerations.
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3.4 Mounting the Hoist
3.4.1 Hook Mounted to a Fixed Location - Attach the hoist’s hook to the fixed suspension point.
3.4.2 The hoist may be mounted by the chain hook or the body hook to a fixed suspension point.
3.5
3.4.3
Ensure that the fixed suspension point rests on the center of the hook’s saddle and that the hook’s latch is engaged.
Electrical Connections
3.5.1
Supplying this hoist with the incorrect power source can lead to serious damage and/or injury. This hoist is reconnectable and is equipped with a quick voltage change device. Check to make sure the power source matches the voltage configuration of the hoist before supplying power to the hoist.
3.5.2 The hoist is equipped with a quick voltage changer inside the controller cover. To configure the hoist to proper voltage configuration, connect the plug from the terminal block to one of the plugs from the contactor marked with the desired voltage configuration.
3.5.3
Figure 3-5 Voltage Changer
Do NOT apply electronic soft-start control or voltage varying controls to the TNER hoist. Use of such devices may cause the motor brake and other electrical components to malfunction.
3.5.4
Before proceeding, ensure that the electrical supply for the hoist has been deenergized (disconnected). Lock out and tag out in accordance with ANSI Z244.1 “Personnel Protection
-Lockout/Tagout of Energy Sources”.
3.5.5 The hoist is supplied with 2.5 feet of power supply cable and 2.5 feet of control cable in a standard configuration. The power supply cable and control cable are directly wired into the hoist.
3.5.6 A pendant (pickle) is optional. In a case where an optional pendant is used, the hoist is controlled by a pendant with two push buttons – one for raising and one for lowering.
3.5.7 Ensure that the power supply cable and the control cord are supported by the Cable Support Assembly and connected to the Socket Holder as shown in Figure 3-6. Use care to avoid twisting or kinking the cables.
13
Standard Cable Exit
Cable Exit for Large Gauge Cable
(Greater than 0.55” Diameter)
Figure 3-6 Cable Support Assembly
3.5.8 Connection to Electrical Power Source - The red, blue and black wires of the Power Supply Cable should be connected to an Electric Power Disconnect Switch or Circuit Breaker. This connection should be made so that the hoist is phased properly. Refer to Section 3.6.10 for instructions on how to check for correct power supply phase connection.
3.5.9 Fuse/Breaker Capacity -The hoist's power supply should be equipped with current overload protection such as fuses, which should be selected for 110% to 120% of total listed full load amperage, and should be dual element time-delay fuses. Refer to the motor nameplate for the full load amperage draw.
3.5.10
Grounding - An improper or insufficient ground connection creates an electrical shock hazard when touching any part of the hoist or trolley. In the Power Supply Cable the ground wire will be either Green with Yellow stripe or solid Green. It should always be connected to a suitable ground connection.
14
3.6 Preoperational Checks and Trial Operation
3.6.1
Confirm the adequacy of the rated capacity for all slings, chains, wire ropes and all other lifting attachments before use. Inspect all load suspension members for damage prior to use and replace or repair all damaged parts.
3.6.2
Section 3.2.
Verify and correct all chain irregularities prior to operating the hoist. Refer to
3.6.3 Measure and record the “k” dimension of all hooks on hoist. See Table 5-4 under Section 5,
“Inspection”.
3.6.4 Record the hoist's Code, Lot and Serial Number (from the name plate on the hoist) in the space provided on the cover of this manual.
3.6.5 Ensure that the hoist is properly installed to a fixed point.
3.6.6 Ensure that all nuts, bolts and split pins (cotter pins) are sufficiently fastened.
3.6.7 If applicable, pull down on the Pendant (Pickle) and ensure that the Cord Strain Relief Cable takes the force, not the Pendant Cord.
3.6.8
Check supply voltage before everyday use. If the voltage varies more than 10% of the rated value, electrical devices may not function normally.
3.6.9 Confirm proper operation.
Before operating read and become familiar with Section 4 - Operation.
Before operating ensure that the hoist (and trolley) meets the Inspection, Testing and Maintenance requirements of ANSI/ASME B30.16.
Before operating ensure that nothing will interfere with the full range of the hoist’s operation.
3.6.10
The hoist must be connected to the power source such that its direction of operation corresponds to the up-and-down commands issued from the pendant (pickle) control; i.e. pushing the UP button must cause the hoist to lift the hook. If the hoist does not operate correctly, shut off and lockout /tagout the main power source to the hoist. Disconnect and switch any two of the three input power leads at the power source to correct the hoist’s motor phasing.
15
4.0 Operation
4.1 Introduction
DO NOT WALK UNDER A SUSPENDED LOAD
HOIST OPERATORS SHALL BE REQUIRED TO READ THE OPERATION SECTION OF THIS MANUAL, THE
WARNINGS CONTAINED IN THIS MANUAL, INSTRUCTION AND WARNING LABELS ON THE HOIST OR
LIFTING SYSTEM, AND THE OPERATION SECTIONS OF ANSI/ASME B30.16 and ANSI/ASME B30.10. THE
OPERATOR SHALL ALSO BE REQUIRED TO BE FAMILIAR WITH THE HOIST AND HOIST CONTROLS
BEFORE BEING AUTHORIZED TO OPERATE THE HOIST OR LIFTING SYSTEM.
HOIST OPERATORS SHOULD BE TRAINED IN PROPER RIGGING PROCEDURES FOR THE ATTACHMENT
OF LOADS TO THE HOIST HOOK.
HOIST OPERATORS SHOULD BE TRAINED TO BE AWARE OF POTENTIAL MALFUNCTIONS OF THE
EQUIPMENT THAT REQUIRE ADJUSTMENT OR REPAIR, AND TO BE INSTRUCTED TO STOP OPERATION
IF SUCH MALFUNCTIONS OCCUR, AND TO IMMEDIATELY ADVISE THEIR SUPERVISOR SO CORRECTIVE
ACTION CAN BE TAKEN.
HOIST OPERATORS SHOULD HAVE NORMAL DEPTH PERCEPTION, FIELD OF VISION, REACTION TIME,
MANUAL DEXTERITY, AND COORDINATION.
HOIST OPERATORS SHOULD NOT HAVE A HISTORY OF OR BE PRONE TO SEIZURES, LOSS OF
PHYSICAL CONTROL, PHYSICAL DEFECTS, OR EMOTIONAL INSTABILITY THAT COULD RESULT IN
ACTIONS OF THE OPERATOR BEING A HAZARD TO THE OPERATOR OR TO OTHERS.
HOIST OPERATORS SHOULD NOT OPERATE A HOIST OR LIFTING SYSTEM WHEN UNDER THE
INFLUENCE OF ALCOHOL, DRUGS, OR MEDICATION.
OVERHEAD HOISTS ARE INTENDED ONLY FOR VERTICAL LIFTING SERVICE OF FREELY SUSPENDED
UNGUIDED LOADS. DO NOT USE HOIST FOR LOADS THAT ARE NOT LIFTED VERTICALLY, LOADS THAT
ARE NOT FREELY SUSPENDED, OR LOADS THAT ARE GUIDED.
• Read ANSI/ASME B30.16 and ANSI/ASME B30.10.
• Read the hoist manufacturer’s Operating and Maintenance Instructions.
• Read all labels attached to equipment.
16
The operation of an overhead hoist involves more than activating the hoist’s controls. Per the ANSI/ASME B30 standards, the use of an overhead hoist is subject to certain hazards that cannot be mitigated by engineered features, but only by the exercise of intelligence, care, common sense, and experience in anticipating the effects and results of activating the hoist’s controls. Use this guidance in conjunction with other warnings, cautions, and notices in this manual to govern the operation and use of your overhead hoist.
4.2 Shall’s and Shall Not’s for Operation
Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in death or serious injury, and substantial property damage.
To avoid such a potentially hazardous situation THE OPERATOR SHALL:
• NOT operate a damaged, malfunctioning or unusually performing hoist.
• NOT apply load unless the load chain is properly seated in its grooves.
• NOT operate a hoist until you have thoroughly read and understood Manufacturer’s Operating and
Maintenance Instructions or Manuals.
• Be familiar with operating controls, procedures, and warnings.
• NOT operate a hoist that has been modified without the manufacturer’s approval or without certification that it is in conformity with ANSI/ASME B30 volumes.
• NOT lift more than rated load for the hoist.
• NOT use hoist with twisted, kinked, damaged, or worn load chain.
• NOT use the hoist to lift, support, or transport people.
• NOT lift loads over people.
• NOT operate a hoist unless all persons are and remain clear of the supported load.
• NOT apply load if bearing prevents equal loading on all load-supporting chain.
• NOT operate beyond the limits of the load chain travel.
• NOT leave load supported by the hoist unattended unless specific precautions have been taken.
• NOT allow the load chain or hook to be used as an electrical or welding ground.
• NOT allow the load chain or hook to be touched by a live welding electrode.
• NOT remove or obscure the warnings on the hoist.
• NOT operate a hoist on which the safety placards or decals are missing or illegible
• NOT operate a hoist unless it has been securely attached to a suitable support.
• NOT operate unless load is centered under hoist.
• NOT attempt to lengthen the load chain or repair damaged load chain.
• Protect the hoist’s load chain from weld splatter or other damaging contaminants.
• NOT operate hoist when it is restricted from forming a straight line from hook to support in the direction of loading.
• NOT use load chain as a sling or wrap load chain around load.
• NOT apply the load to the tip of the hook or to the hook latch.
• NOT operate a hoist unless load slings or other approved single attachments are properly sized, and seated in the hook saddle.
• NOT use the hoist in such a way that could result in shock or impact loads being applied to the hoist.
• Take up slack carefully – make sure load is balanced and load-holding action is secure before continuing.
• Shut down a hoist that malfunctions or performs unusually and report such malfunction.
• Make sure hoist limit switches function properly.
• Warn personnel before lifting or moving a load.
• Warn personnel of an approaching load.
17
Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in minor or moderate injury, or property damage. To avoid such a potentially hazardous situation THE
OPERATOR SHALL:
• Maintain a firm footing or be otherwise secured when operating the hoist.
• Check brake function by tensioning the hoist prior to each lift operation.
• Use hook latches. Latches are to retain slings, chains, etc. under slack conditions only.
• Make sure the hook latches are closed and not supporting any parts of the load.
• Make sure the load is free to move and will clear all obstructions.
• Avoid swinging the load or hook.
• Make sure hook travel is in the same direction as shown on controls.
• Inspect the hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance.
4.3 Hoist Controls
4.3.1 Emergency Stop Button – On hoists equipped with Emergency Stop functionality, press the Emergency
Stop Button to perform an emergency stop and lock-out of hoist motion controls. Turn the Emergency Stop
Button clockwise to unlock the controls and allow hoist operation.
4.3.2 When using the pendant control
(pickle) depress the UP button to raise the hoist load chain/hook or the
DOWN button to lower the hoist load chain/hook as shown in Figure 4-1.
To stop motion release the buttons.
• Use the hoist manufacturer’s recommended parts when repairing the unit.
• Lubricate load chain per hoist manufacturer’s recommendations.
• NOT use the hoist load limiting or warning device to measure load.
• NOT use limit switches as routine operating stops.
They are emergency devices only.
• NOT allow your attention to be diverted from operating the hoist.
• NOT allow the hoist to be subjected to sharp contact with other hoists, structures, or objects through misuse.
• NOT adjust or repair the hoist unless qualified to perform such adjustments or repairs.
4.3.3
reversing direction.
Make sure the motor completely stops before
Figure 4-1 Push Button Pendant Control
(Pickle)
18
5.0 Inspection
5.1 General
5.1.1 The inspection procedure herein is based on ANSI/ASME B30.16. The following definitions are from
ANSI/ASME B30.16 and pertain to the inspection procedure below. An additional definition from ANSI
PLASA E1.6-2 is included for Rental Service.
Designated Person – a person selected or assigned as being competent to perform the specific duties to which he/she is assigned.
Qualified Person – a person who, by possession of a recognized degree or certificate of professional standing, or who, by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.
Normal Service – that distributed service which involves operation with randomly distributed loads within the rated load limit, or uniform loads less than 65% of rated load for not more than 25% of the time.
Heavy Service – that service which involves operation within the rated load limit which exceeds normal service.
Severe Service – that service which involves normal or heavy service with abnormal operating conditions.
Rental Service – that service which involves an irregular schedule determined by rental use.
5.2 Inspection Classification.
5.2.1 Initial Inspection – prior to initial use, all new, altered, or modified hoists shall be inspected by a designated person to ensure compliance with the applicable provisions of this manual.
5.2.2 Inspection Classification – the inspection procedure for hoists in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the hoist and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as FREQUENT and PERIODIC, with respective intervals between inspections as defined below.
5.2.3 FREQUENT Inspection – visual examinations by the operator or other designated personnel with intervals per the following criteria:
Normal service – monthly
Heavy service – weekly to monthly
Severe service – daily to weekly
Rental service – prior to next use or rental
Special or infrequent service – as recommended by a qualified person before and after each occurrence.
5.2.4 PERIODIC Inspection – visual inspection by a designated person with intervals per the following criteria:
Normal service – yearly
Heavy service – semiannually
Severe service – quarterly
Rental service – prior to next use or rental
Special or infrequent service – as recommended by a qualified person before the first such occurrence and as directed by the qualified person for any subsequent occurrences.
19
5.3 Frequent Inspection
5.3.1 Inspections should be made on a FREQUENT basis in accordance with Table 5-1, “Frequent Inspection.”
Included in these FREQUENT Inspections are observations made during operation for any defects or damage that might appear between Periodic Inspections. Evaluation and resolution of the results of
FREQUENT Inspections shall be made by a designated person such that the hoist is maintained in safe working condition.
Table 5-1 Frequent Inspection
All functional operating mechanisms for maladjustment and unusual sounds
Operation of limit switch and associated components
Hoist braking system for proper operation
Hooks in accordance with ANSI/ASME B30.10
Hook latch operation
Load chain in accordance with Section 5.7
Load chain reeving for compliance with Section 3.2 and 6.3
5.4 Periodic Inspection
5.4.1 Inspections should be made on a PERIODIC basis in accordance with Table 5-2, “Periodic Inspection.”
Evaluation and resolution of the results of PERIODIC Inspections shall be made by a designated person such that the hoist is maintained in safe working condition.
5.4.2 For inspections where load suspension parts of the hoist are disassembled, a load test per ANSI/ASME
B30.16 must be performed on the hoist after it is re-assembled and prior to its return to service.
Table 5-2 Periodic Inspection
Requirements of frequent inspection.
Evidence of loose bolts, nuts, or rivets.
Evidence of worn, corroded, cracked, or distorted parts such as load blocks, suspension housing, chain attachments, clevises, yokes, suspension bolts, shafts, gears, bearings, pins and rollers.
Evidence of damage to hook retaining nuts or collars and pins, and welds or rivets used to secure the retaining members.
Evidence of damage or excessive wear of load and idler sheaves.
Evidence of excessive wear on motor or load brake.
Electrical apparatus for signs of pitting or any deterioration of visible controller contacts.
Evidence of damage of supporting structure or trolley, if used.
Function labels on pendant control stations (pickles) for legibility.
Warning label properly attached to the hoist and legible (see Section 1.2).
End connections of load chain.
20
5.5 Occasionally Used Hoists
5.5.1 Hoists that are used infrequently shall be inspected as follows prior to placing in service:
Hoist Idle More Than 1 Month, Less Than 1 Year: Inspect per FREQUENT Inspection criteria in
Section 5.3.
Hoist Idle More Than 1 Year: Inspect per PERIODIC Inspection criteria in Section 5.4.
Rental Service Hoists – Inspect per FREQUENT Inspection criteria in Section 5.3 prior to next use or rental.
5.6 Inspection Records
5.6.1 Dated inspection reports and records should be maintained at time intervals corresponding to those that apply for the hoist’s PERIODIC interval per Section 5.2.4. These records should be stored where they are available to personnel involved with the inspection, maintenance, or operation of the hoist.
5.6.2 A long range chain inspection program should be established and should include records of examination of chains removed from service so a relationship can be established between visual observation and actual condition of the chain.
5.7 Inspection Methods and Criteria
5.7.1 This section covers the inspection of specific items. The list of items in this section is based on those listed in ANSI/ASME B30.16 for the Frequent and Periodic Inspection. In accordance with ANSI/ASME B30.16, these inspections are not intended to involve disassembly of the hoist. Rather, disassembly for further inspection would be required if frequent or periodic inspection results so indicate. Such disassembly and further inspection should only be performed by a qualified person trained in the disassembly and reassembly of the hoist.
Item
Functional operating mechanisms.
Limit Switch
Limit Lever
Assembly
Braking System
Operation
Hooks - Surface
Condition
Hooks - Fretting wear
Hooks - Stretch
Hooks - Bent Shank or Neck
Table 5-3 Hoist Inspection Methods and Criteria
Method Criteria
Visual, Auditory Mechanisms should be properly adjusted and should not produce unusual sounds when operated.
Function
Visual, Function Lever should not be bent or significantly worn and should be able to move freely.
Function
Proper operation. Actuation of limit switch should stop hoist.
Visual
Braking distance with rated capacity should not exceed 3% of the lifting speed (approximately two chain links).
Should be free of significant rust, weld splatter, deep nicks, or gouges.
Measure
Measure
Visual
The "u" and "t" dimensions should not be less than discard value listed in Table 5-4
The "k" dimension should not be greater than
1.15 times that measured and recorded at the time of purchase (See Section 3.6
). If recorded
"k" values are not available for hooks when new, use nominal "k" values from Table 5-4.
Shank and neck portions of hook should be free of deformations.
Action
Repair or replace as required.
Repair or replace as required.
Replace.
Repair or replace as required.
Replace.
Replace.
Replace.
Replace.
21
Item
Hooks - Yoke
Assembly
Hooks - Swivel
Bearing
Hooks - Idle Sheave and Axle (Chain
Hook on Double Fall
Hoist)
Hooks - Hook
Latches
Load Chain -
Surface Condition
Load Chain - Pitch and Wire Diameter
Load Chain -
Lubrication
Load Chain -
Reeving
Chain Container
Housing and
Mechanical
Components
Table 5-3 Hoist Inspection Methods and Criteria
Method Criteria
Visual Should be free of significant rust, weld splatter, nicks, gouges. Holes should not be elongated, fasteners should not be loose, and there should be no gap between mating parts.
Visual, Function Bearing parts and surfaces should not show significant wear, and should be free of dirt, grime and deformations. Hook should rotate freely with no roughness.
Visual, Function Pockets of Idle Sheave should be free of significant wear. Idle Sheave surfaces should be free of nicks, gouges, dirt and grime. Bearing parts and surfaces of Idle Sheave and Axle should not show significant wear. Idle Sheave should rotate freely with no roughness or significant free play.
Visual, Function Latch should not be deformed. Attachment of latch to hook should not be loose. Latch spring should not be missing and should not be weak.
Latch movement should not be stiff - when depressed and released latch should snap smartly to its closed position.
Visual Should be free of rust, nicks, gouges, dents and weld splatter. Links should not be deformed, and should not show signs of abrasion. Surfaces where links bear on one another should be free of significant wear.
Measure The "P" dimension should not be greater than maximum value listed in Table 5-5. The "d" dimension should not be less than minimum value listed in Table 5-5.
Visual, Auditory Entire surface of each chain link should be coated with lubricant and should be free of dirt and grime.
Chain should not emit cracking noise when hoisting a load.
Visual
Visual
Chain should be reeved properly through Load
Sheave (and Idle Sheave for double fall hoist) - refer to Section 6.3
. Chain, Chain Coupling,
Chain Clip and Ball Stopper should be installed properly - refer to Section 3.2
.
Container should not be damaged. Brackets should not be deformed or missing.
Visual, Auditory,
Vibration,
Function
Hoist components including load blocks, suspension housing, chain attachments, clevises, yokes, suspension bolts, shafts, gears, bearings, pins and rollers should be free of cracks, distortion, significant wear and corrosion.
Evidence of same can be detected visually or via detection of unusual sounds or vibration during operation.
22
Action
Tighten or replace as required.
Clean/lubricate, or replace as required.
Clean/lubricate, or replace as required.
Replace.
Replace.
Replace. Inspect
Load Sheave (and
Idle Sheave for double fall hoist).
Clean/lubricate
(see Section 6.0
).
Reeve/Install chain properly.
Replace.
Replace.
Item
Bolts, Nuts and
Rivets
Motor Brake Measure, Visual Motor brake gap should be adjusted to the distance shown in Table 6-1 before measuring the brake wear. Brake lining dimension “A” should not be less than discard value listed in
Table 5-6.
Refer to Section 6.2
for gaining access to motor brake and for adjustment and inspection procedures. Braking surfaces should be clean, free of grease/oil and should not be glazed.
Contactor Contacts Visual
Load Sheave Visual
Contacts should be free of significant pitting or deterioration.
Pockets of Load Sheave should be free of significant wear.
Pendant (Pickle) –
Switches
(Optional)
Table 5-3 Hoist Inspection Methods and Criteria
Method Criteria
Visual, Check with Proper Tool
Bolts, nuts and rivets should not be loose.
Function
Visual
Depressing and releasing push-buttons should make and break contacts in switch contact block and result in corresponding electrical continuity or open circuit. Push-buttons should be interlocked either mechanically or electrically to prevent simultaneous energization of circuits for opposing motions (e.g. up and down).
Pendant housing should be free of cracks and mating surfaces of parts should seal without gaps.
Pendant (Pickle) -
Housing
(Optional)
Pendant (Pickle) -
Wiring
(Optional)
Pendant (Pickle) -
Cord
Visual
Visual, Electrical
Continuity
Wire connections to switches in pendant should not be loose or damaged.
Pendant (Pickle) -
Labels
Warning Labels
Visual
Visual
Surface of cord should be free from nicks, gouges, and abrasions. Each conductor in cord should have 100% electrical continuity even when cord is flexed back-and-forth. Pendant Cord
Strain Relief Cable should absorb all of the load associated with forces applied to the pendant.
Labels denoting functions should be legible.
Hoist Capacity Label Visual
Warning Labels should be affixed to the hoist (see
Section 1.2
) and they should be legible.
The label that indicates the capacity of the hoist should be legible and securely attached to the hoist.
Action
Tighten or replace as required.
Adjust, Repair or
Replace as required.
Replace.
Replace.
Repair or replace as necessary.
Replace.
Tighten or repair.
Replace.
Replace.
Replace.
Replace.
23
Table 5-4 Chain Hook & Bottom Hook Dimensions
“k” Measured When New:
Chain: ________________________
Body: ________________________
C = Chain Hook
B = Body Hook
Capacity Code
Nominal "k"
Dimension * inch (mm)
"u" Dimension inch (mm)
Standard Discard
"t" Dimension inch (mm)
Standard Discard
005L
010L,
010S
C
B
C
B
1.65 (42)
1.92 (48.8)
1.97 (50)
2.22 (56.3)
0.93 (23.5)
0.86 (21.8)
1.22 (31)
1.04 (26.5)
0.83 (21)
0.77 (19.6)
1.10 (28)
0.94 (23.9)
0.69 (17.5)
0.63 (16.0)
0.89 (22.5)
0.77 (19.5)
0.63 (16)
0.57 (14.4)
0.79 (20)
0.69 (17.6)
020L,
020S
C
B
2.46 (62.5)
2.52 (64.1)
1.57 (40)
1.32 (33.5)
1.42 (36)
1.19 (30.2)
1.14 (29)
0.96 (24.3)
1.02 (26)
0.86 (21.9)
* These values are nominal since the dimension is not controlled to a tolerance. The "k" dimension should be measured when the hook is new - this becomes a reference measurement. Subsequent measurements are compared to this reference to make determinations about hook deformation/stretch. See Section 5.7, “Hooks - Stretch”.
Table 5-5 Chain Wear Dimensions
Capacity Code
005L
010L/S, 020L/S
“P” Dimension inch (mm)
Standard Discard
3.76
(95.5)
3.82 (96.9)
4.76
(121.0)
4.91 (124.6)
“d” Dimension inch (mm)
Standard Discard
0.25 (6.3) 0.22 (5.7)
0.31 (8.0) 0.28 (7.2)
24
Table 5-6 Motor Brake Wear Dimensions
Capacity Code
005L
010L/S, 020L/S
Brake must be properly adjusted before measuring "A". See Section 6.3
"A" Dimension - inch (mm)
Standard Discard
0.67 (17) 0.61 (15.5)
0.85 (21.5) 0.79 (20)
25
6.0
Maintenance and Handling
6.1 Lubrication
6.1.1 Load Chain
For longer life, the load chain should be lubricated.
The load chain lubrication should be accomplished after cleaning the load chain with an acid free cleaning solution.
Apply Harrington lubricating grease (Part No. ER1BS1951) or an equivalent to industrial general lithium grease, NLGI No. 0, to the bearing surfaces of the load chain links as indicated by the shaded areas in
Figure 6-1. Also apply the grease to the areas of the load chain (shaded areas in Figure 6-1) that contact the load sheave. Insure that the grease is applied to the contact areas in the load sheave pockets.
Machine or gear oil (grade ISO VG 46 or 68 oil or equivalent) may be used as an alternative lubricant but must be applied more frequently.
Figure 6-1 Chain Grease Application
The chain should be lubricated every 3 months (more frequently for heavier usage or severe conditions).
For dusty environments, it is acceptable to substitute a dry lubricant.
6.1.2 Hooks and Suspension Components:
Hooks - Bearings should be cleaned and lubricated at least once per year for normal usage. Clean and lubricate more frequently for heavier usage or severe conditions.
Suspension Pins - Lubricate at least twice per year for normal usage; more frequently for heavier usage or severe conditions.
Idle Sheave Bearing - Bearings should be cleaned and lubricated at least twice per year for normal usage. Clean and lubricate more frequently for heavier usage or severe conditions.
Oil Seal (020L /S Hook Yoke) – In order to avoid liquefied grease leaking, make sure to replace the oil seal when replacing the idle sheave assembly.
26
6.1.3 Gear Box:
Using an incorrect type/grade of gearbox grease or the wrong quantity of grease may prevent the friction clutch from working properly and may affect the ability of the hoist to hold the load. Refer to Section 3.1 for the correct grease and quantity.
If experiencing abnormal noise or unusual gearbox operation, have the gearbox serviced by a qualified individual.
Always replace the gearbox grease when servicing the gearbox. Gear grease is Sumiplex L-Mo No.1
(Part No. SA1BS1855).
Product Code Grease Amount
005L, 010L/S, 020L/S 3.2 oz. (90 grams)
Dispose of the used grease in accordance with local regulations.
6.2 Motor Brake
6.2.1 To keep your hoist working in optimum condition and prevent possible down time, it is recommended to check your motor brake lining and adjustment at regular intervals.
6.2.2 Motor Brake Unit Removal - Adjustment and inspection of the motor brake requires removal of the motor brake unit from the hoist as an assembly.
1)
Before proceeding disconnect the power supply and make sure the hoist is unloaded.
To keep the load chain from moving secure it by tying together the load and no-load sides directly under the hoist using a cord or wire.
2) Refer to Figure 6-3.
3) Remove the four Frame Cover Bolts (A), Frame Cover (B), Nut (C), Lock Washer (D), and Spacer (E).
4) Remove the four Motor Cover Assembly bolts (F) and carefully pull the motor brake unit (G) out of the hoist.
27
Figure 6-2 Motor Brake
6.2.3 Brake Gap (G) - The Brake Gap should be measured between the Brake Drum and Pull Rotor. Adjustment of the Brake Gap is accomplished by turning the Adjustment Nut in the center of the Motor Cover as shown in the figure with Table 6-1. Do this as follows:
5) Bend the tab of the Lock Washer away from the Adjusting Nut so that the Adjusting Nut can be rotated.
6) Using a spanner wrench and a feeler gauge, rotate the Adjusting Nut to attain the proper Brake Gap per
Table 6-1.
7) After the Brake Gap is set, secure the Adjusting Nut by bending one of the tabs of the Lock Washer into a slot in the Adjusting Nut. If necessary rotate the Adjusting Nut clockwise (tightening) to line up the tab with the slot.
8) If the proper brake adjustment cannot be achieved, disassemble the motor brake and inspect all motor brake parts. Replace the Brake Drum and/or Motor Cover if necessary.
28
Table 6-1 Motor Brake Gap
Brake Gap (G) inch (mm)
0.020 (0.5)
6.2.4 Brake Lining Inspection –The brake lining is designed for a long life and should provide years of trouble-free service. If the brake lining is being inspected due to excessive load chain drift during operation (see Section
5.7), disassemble the motor brake and inspect all motor brake parts. Braking surfaces should be clean, free of grease/oil and should not be glazed. Replace the Brake Drum and/or Motor Cover if necessary. For normal inspections, the Brake Lining and Motor Cover wear should be measured as follows.
1) Adjust the Brake Gap per Section 6.2.3 before measuring the Brake Lining and Motor Cover wear.
2) Refer to Table 5-6.
3) Measure the distance "A" using calipers and a straight edge. Place the straight edge across the edge of the motor cover and measure from the straight edge to the face of the Pull Rotor.
4) Compare the measurement with the values listed in Table 5-6. Replace the Brake Drum and/or Motor
Cover if the "A" measurement is smaller than the discard limit.
6.2.5 Motor Brake Unit Installation - After the brake is properly adjusted and inspected, carefully replace the motor brake unit back into the hoist. Be sure to reseal the Motor Cover to motor frame surface using a small bead of liquid (hi-temperature) sealant. Refer to Section 6.2.2 and reassemble the parts in reverse order of removal.
6.3 Load Chain
6.3.1 Lubrication and Cleaning – refer to Section 6.1.
6.3.2 Load Chain Replacement:
1)
procedures.
6.3.3
The hoist must be properly powered and operational in order to perform the following
Be certain that the replacement chain is obtained from Harrington and is the exact size, grade and construction as the original chain. The new load chain must have an odd number of links so that
29
both its end links have the same orientation. If the load chain is being replaced due to damage or wear out, destroy the old chain to prevent its reuse.
1)
When replacing load chain, check for wear on mating parts, i.e. Load Sheave, Chain
Guides and Idle Sheaves, and replace parts if necessary.
2) Remove all chain components including the Chain Hook Set Assembly, Ball Stoppers, Chain Pin, Chain
Coupling and Chain Clip from the chain for reuse on new chain. Inspect and replace any damaged or worn parts.
3) Using a C-link, attach the new chain to the end link of the old chain on the no-load side. The end link of the new load chain should be connected so that the welded portions of the load chain's standing links are oriented to the outside as they pass over the sheave. Refer to Figure 6-3.
4) Operate the hoist down to move the chain though the hoist body. Stop when a sufficient amount of new chain is accumulated on the load side.
5) Single fall hoists - Attach the chain components (step 4 above) to the chain. Refer to Section 3.2 for the proper locations.
6) Double falls (020L/S) - Feed the end link on the load side of the new chain through the required chain components (step 4 above) and the bottom hook’s Idle Sheave. Attach the remaining chain components to the chain referring to Section 3.2 for the proper locations. Connect the end link to the top connection yoke with the chain pin, slotted nut and cotter pin. Ensure that chain remains free of twists. Refer to Figures 3-3 and 3-4.
7)
Section 3.2.
Make sure Ball Stopper, Chain Coupling and Chain Clip are properly installed. Refer to
8) After installation has been completed, perform steps outlined in Section 3.6 "Preoperational Checks and
Trial Operation".
30
Figure 6-3 Chain Replacement
6.4 Friction Clutch
6.4.1 Friction Clutch – If abnormal operation or slippage occurs do NOT attempt to disassemble or adjust the
Friction Clutch. Replace the worn or malfunctioning Friction Clutch as an assembly with a new, factory adjusted part.
6.5 Storage
6.5.1 The storage location should be clean and dry.
6.6 Outdoor Installation
6.6.1 For hoist installations that are outdoors, the hoist should be covered when not in use.
6.6.2 Possibility of corrosion on components of the hoist increases for installations where salt air and high humidity are present. Make frequent and regular inspections of the unit's condition and operation.
31
7.0
Troubleshooting
HAZARDOUS VOLTAGES ARE PRESENT IN THE HOIST AND IN CONNECTIONS BETWEEN
COMPONENTS.
Before performing ANY troubleshooting on the equipment, de-energize the supply of electricity to the equipment, and lock and tag the supply device in the de-energized position. Refer to ANSI Z244.1, “Personnel Protection -
Lockout/Tagout of Energy Sources.”
Only Trained and competent personnel should inspect and repair this equipment.
Symptom
Hoist moving in wrong direction
Hoist will not operate
Cause
Table 7-1 Troubleshooting Guide
Power supply reversed phased
Remedy
Switch 2 of the 3 power supply cord wires at the power source.
Improper electrical connections
Refer to wiring diagram and check all connections.
Loss of power
Wrong voltage or frequency
Hoist overload
Motor overheated and thermal overload protector has tripped
Improper, loose, or broken wire in hoist electrical system
Check circuit breakers, switches, fuses and connections on power lines/cable.
Check voltage and frequency of power supply against the rating on the nameplate of the motor.
Reduce load to within rated capacity of hoist.
See Trouble Shooting Problem "Motor or brake overheating".
Shut off power supply, check wiring connections on hoist control panel and inside push-button pendant.
Brake does not release
Faulty magnetic contactor
Defect in control transformer
Motor burned out
Check motor brake adjustment for proper clearance.
Check coil for open or short circuit. Check all connections in the control circuit. Check for open contactors. Replace as needed.
Check transformer coil for signs of overheating. Disconnect transformer and check for open winding.
Replace motor frame/stator, shaft/rotor, and any other damaged parts.
32
lower
Symptom
Hoist lifts but will not
Hoist lowers but will not lift
Hoist will not lift rated load or does not have the proper lifting speed
Load drifts excessively when hoist is stopped
Cause
Table 7-1 Troubleshooting Guide
Down circuit open
Remedy
Check circuit for loose connections. Check down side of limit switch for malfunction.
Broken conductor in pendant (pickle) cord
Check the continuity for each conductor in the cable. If one is broken, replace entire cable.
Faulty magnetic contactors
Faulty switch in pendant (pickle)
Hoist overloaded
Check coils for open or short circuit. Check all connections on motor circuit. Check for burned contacts. Replace as needed.
Check electrical continuity. Check electrical connections.
Replace or repair as needed.
Reduce load to within rated capacity of hoist.
Low voltage in hoist's power supply
Up circuit open
Determine cause of low voltage and bring to within plus or minus
10% of the voltage specified on the motor nameplate. The voltage should be measured at the hoist contactor.
Check circuit for loose connections. Check up side of limit switch for malfunction.
Check the continuity of each conductor in the cable. If one is broken, replace entire cable.
Broken conductor in pendant (pickle) cord
Faulty magnetic contactor
Faulty switch in pendant (pickle)
Faulty friction clutch
Hoist overloaded
Low voltage in hoist's power supply
Brake drags
Faulty friction clutch
Check coils for open or short circuit. Check all connections on motor circuit. Check for burned contacts. Replace as needed.
Check electrical continuity. Check electrical connections.
Replace or repair as needed.
Replace.
Reduce load to within rated capacity.
Determine cause of low voltage and bring to within plus or minus
10% of voltage specified on the motor nameplate. The voltage should be measured at the hoist contactor.
Check motor brake adjustment for proper clearance.
Replace.
Motor brake not holding
Clean and inspect brake lining. Check brake adjustment for proper clearance.
33
Symptom
Motor or brake overheating
Hoist operates intermittently
Cause
Excessive load
Table 7-1 Troubleshooting Guide
Remedy
Reduce load to within rated capacity of hoist.
Excessive duty cycle
Wrong voltage or frequency
Brake drags
Reduce frequency of lifts.
Check voltage and frequency of power supply against the rating on the nameplate on the motor.
Check brake adjustment for proper clearance.
Extreme external heating
Above an ambient temperature of 140°F, the frequency of hoist operation must be reduced to avoid overheating of the motor.
Special provisions should be made to ventilate the hoist or otherwise shield it from the heat.
Check movement of spring loaded arm, weak spring, connections, and shoe. Replace as needed.
Collectors making poor contact
Contactor contacts arcing
Loose connection in circuit
Broken conductor in
Pendant (Pickle) Cord
Check for burned contacts. Replace as needed.
Check all wires and terminals for bad connections. Replace as needed.
Check for intermittent continuity in each conductor the Pendant
Cord. Replace entire Pendant Cord if continuity is not constant.
34
8.0 Warranty
Warranty explanation and terms.
All products sold by Harrington Hoists, Inc. are warranted to be free from defects in material and workmanship from date of shipment by Harrington for the following periods:
1 year – Electric and Air Powered Hoists (excluding (N)ER2 Enhanced Features Models and
EQ/SEQ Models ), Powered Trolleys, Powered Tiger Track Jibs and Gantries, Crane
Components, Below the Hook Devices, Spare / Replacement Parts
2 years – Manual Hoists & Trolleys, Beam Clamps
3 years – (N)ER2 Enhanced Features Hoists, EQ/SEQ Hoists, and RY Hoists
5 years – Manual Tiger Track Jibs and Gantries, TNER, EQ/SEQ, and RY Hoist Motor Brakes
10 years – (N)ER2 “The Guardian” Smart Brake
The product must be used in accordance with manufacturer’s recommendations and must not have been subject to abuse, lack of maintenance, misuse, negligence, or unauthorized repairs or alterations.
Should any defect in material or workmanship occur during the above time period in any product, as determined by Harrington Hoist’s inspection of the product, Harrington Hoists, Inc. agrees, at its discretion, either to replace (not including installation) or repair the part or product free of charge and deliver said item F.O.B. Harrington Hoists, Inc. place of business to customer.
Customer must obtain a Return Goods Authorization as directed by Harrington or Harrington’s published repair center prior to shipping product for warranty evaluation. An explanation of the complaint must accompany the product. Product must be returned freight prepaid. Upon repair, the product will be covered for the remainder of the original warranty period. Replacement parts installed after the original warranty period will only be eligible for replacement (not including installation) for a period of one year from the installation date. If it is determined there is no defect, or that the defect resulted from causes not within the scope of Harrington’s warranty, the customer will be responsible for the costs of returning the product.
Harrington Hoists, Inc. disclaims any and all other warranties of any kind expressed or implied as to the product’s merchantability or fitness for a particular application. Harrington will not be liable for death, injuries to persons or property or for incidental, contingent, special or consequential damages, loss or expense arising in connection with the use or inability whatever, regardless of whether damage, loss or expense results from any act or failure to act by Harrington, whether negligent or willful, or from any other reason.
35
9.0 Parts List
When ordering Parts, please provide the Hoist code number, lot number and serial number located on the Hoist nameplate
(see fig. below).
Reminder: Per sections 1.1 and 3.6.4 to aid in ordering Parts and Product Support, record the Hoist code number, lot number and serial number in the space provided on the cover of this manual.
The parts list is arranged into the following sections:
Section Page
9.1 Housing and Motor Parts……………………………………………….…………………………….. 38
9.2 Gearing Parts…………………………………………………………………………………………... 42
9.3 Hook Parts………………………………………………………………….………………………….. 44
9.4 Chaining Parts…………………………………………………………...…………………………….. 46
9.5 Electric Parts…………………………………………………………….……………………………... 48
9.6 Power Supply and Pendant (Pickle) Parts……………………………………...……………………. 50
36
This Page Intentionally Left Blank
Figure 9-1 Housing and Motor Parts
Figure
No.
Part Name
1 Frame Cover
2 Socket Bolt
3 Toothed Lock Washer
8 Nut
9 Lock Washer
10 Spacer
11 Motor Cover Assembly
12 Socket Bolt
13 Spring Washer
14 Collar M
15 Coned Disc Spring M
16 Brake Drum Assembly
17 Brake Spring
18 Thrust Collar
19 Thrust Disc
20 Pull Rotor
21 Coned Disc Spring
22 Motor Shaft with Rotor
24
Motor Frame with Stator
208-230/460V-3-60
25 Socket Bolt
26 Set Pin S
27 Packing M
28 Body B
30 Oil Plug
31 Plug Packing
32 Set Pin S
33 Packing G
35 Gear Case F
36 Socket Bolt
37 Toothed Lock Washer
1
2
2
1
1
4
4
1
1
2
4
2
Parts Per
Hoist
1
4
4
1
1
1
1
4
1
2
1
1
4
1
4
1
1
1
005L
SA1BL9207
SA1BL9313
ER1BS2106
9091251
9012709
ER1BS5212
ES214003
ES506003
ES505003
ES503003
ES504003
SA1BL5502
SA1DHM05L5A12
90912138
ES120003
ER1BS9118
SA1BL9101
ER1BS9116
SA1BL9103
010L 020L
SA1CL9207
9091233
9679708
ES217005S
ES218005S
ES216S005
ES192005S
E3S191005S
ER1CS2106
9091273
9012711
ER1CS5212
ES214005S
ES506005S
ES505005S
ES503005S
ES504005S
SA1CL5502
010S
SA1CS9207
SA1BL9313
EP1CS5212
SA1CS9214
ES506003
ES505003
ES503003
ES504003
SA1CS5502
020S
SA1DHM10S5A11 SA1DHM010L5A12
9091275
ES120010S
SA1CL9101
E3S111003
ER1CS9118
E3S112003
ES1200035
ER1CS9116
SA1CL9103
9091259
9679709
SA1CS7101
Figure
No.
Part Name
38 Name Plate SP
39 Oil Plug B
40 Eyebolt Packing
42 Bending Washer
43 Spring Pin
44 Handle Kit
45 Hex Bolt
48 Packing C
50 Socket Bolt
51 Toothed Lock Washer
52 Name Plate B
62 Name Plate D
53
Warning Sticker E
(Disconnect Power)
55 Grease Warning Label
56
Voltage Changer Warning
Label
57 KREWMATE Logo Label
58 BGV-D8 Logo Label
59 CE Mark Label
60 Controller Cover
61 Wiring Diagram
1
1
1
1
1
1
1
1
4
2
4
4
1
1
Parts Per
Hoist
1
2
1
1
1
1
005L
80519
ER1BS9117
9091238
80815
SA1BL9104
010L
80520
020L 010S
80507
SA1BS9135
ES127005S
SA1BS9983
E3S129005S
SA1BL59631
J1BK10601515
ER1CS9117
9091239
80551
9679708
80817
80506
ER2CS9936
80470
80485
80776
80486
80487
SA1CL9104
EWE4A00H1
SA1CS9104
020S
80531
80506
This Page Intentionally Left Blank
Figure 9-2 Gearing Parts
Figure
No.
Part Name
1 Bearing Holder
2 Socket Bolt
3 Snap Ring
4 Collar B
5 Pinion Assembly
6 Oil Seal
7 Ball Bearing
8* Load Sheave
9 Oil Seal
10 Ball Bearing
11 Snap Ring
12 Load Gear
13 Snap Ring
14 Ball Bearing
15 Ball Bearing
16 Friction Clutch Set
1
1
1
1
1
1
1
1
Parts Per
Hoist
1
3
1
1
1
1
1
1
005L
9047262
ER1BS9111
ER1BS5220
ES221003
9000907
70985
ES232005S
9047262
ER1BL9240
9047130
9001001
9000301
SA1BL1626
17
18
19
20
21
22
23
24
Wavy Washer
Oil Seal
Friction Plug
Nameplate FP
Set Pin S
Gear Plate
Spring Washer
Socket Bolt
2
1
3
3
2
1
1
1
1
1
ES221005S
ER1BS9235
25 Ball Bearing
26 Gear B Assembly
27 Grease Guard
2
1
1
28 Guard Plate 1
*Kit includes Chain Guide A and Chain Guide B, see pages 48 and 49.
010L 020L 010S
ER1CS9110
90912133
9047262
SA1CL5220
ES221010S
9000909
70986
ES232005S
9000907
9047262
ER1CS9240
9047135
9001101
SA1CL1626
E1DBX20S9311
9000204
E6F235003S
ER1BS9892
ER1CS9235
ES120003
ER1CL9261
9012709
90912138
70987
SA1CS9240
SA1CS1626
020S
J1BA10604040
90912138
9000900
SA1CL5262 SA1CS5262
SA1CS9109
SA1CS9656
Figure 9-3 Hook Parts
Figure
No.
Part Name
Parts Per
Hoist
005L 010L 020L 010S 020S
2
3
7
8
5
6
9
10
11
16
18
19
20
12
13
14
15
Quick Link
Suspender D
Yoke Bolt
Slotted Nut
Split Pin
Body Hook Complete Assembly
Hook Latch Assembly
Chain Pin
Slotted Nut
Split Pin
Connection Shaft
O Ring
Plate A
Machine Screw w/ Spring Washer
Fixing Shaft Assembly
O Ring
Shaft Plug
22
26
Machine Screw
Chain Hook Complete Assembly
28 Hook Latch Assembly
29 Thrust Collar A
30 Hook Stopper
31 Thrust Bearing
32 Bottom Shaft Assembly
33 Idle Sheave Assembly
34 Bottom Yoke Assembly
35 Bolt
36 Spring Washer
37 Nut
38
39
Name Plate C
Ball Stopper Set
40
41
42
Load Chain (Nickel Plated DIN)
Load Chain (Black)*
Chain Coupling
Socket Bolt w/ Spring Washer
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
2
1
2
1
1
1
1
1
1
1
1
4
4
1
4
2
SA1BS1001
CF071010
ER1BS9121
9013306
ER1BS1122
ER1BS9128
SA1BL1011
ER1BS1002
ES026003
ES027003
ES022003
SA1CS9041
LCER005NP-DIN
LCER005C
J1BG10602020
SA1CS1001
CF071015
ER1BS9123
J1AP25001212
SA1CL1011
ER1DS1002
9010205
Ver. A: SA1CR90301
Ver. B: SA1CR90302
SA1CR9032
ES088020L
9009436
SA1CR1001
CF071030
Ver. A: M2041010
Ver. B: M2041020
Ver. A: M2049010
Ver. B: M2049020
9009412
ER1CS9121
9013309
SA1CS1001
CF071015
ER1CS1122
9013305
ER1CS9128
9798543
SA1CR1011 SA1CL1011
ER1ES1002 ER1DS1002
ES026010L
ES027010L
ES022010L
ER2DR6023
27SH010S1103
SA1CR2015
90931215
9012711
9093424
M3805030
SA1CL9041
LCER010NP-DIN
LCER010C
P2HC0051121
J1BG10602525
*The black load chain is optional. The hoist will not have CE Conformance with the black chain installed.
SA1CR90302
SA1CR9032
ES088020L
9009436
SA1CR1001
CF071030
M3041020
M2049020
9009412
SA1CS9123
J1BE10505518
SA1CR1011
ER1ES1002
ER2DR6023
27SH010S1103
SA1CR2015
90931215
9012711
9093424
M3805030
Figure 9-4 Chaining Parts
Fig No Part Name
1 Chain Guide A
3 Guide Roller
4 Roller Pin
5 Limit Lever S
10 Chain Guide B
11 Mach. Screw w/ Spring Washer
12 Socket Bolt w/ Spring Washer
14 Limit Lever Pin Assembly
17 Split Pin
21 Body Plate
22 Socket Bolt
23 Flat Washer
24 Spring Washer
25 Nut
26 Socket Bolt
27 Spring Washer
28 Nut
29 Chain Guide C
30 Socket Bolt
31 Spring Washer
32 Nut
10” TNER Chain Container
13” TNER Chain Container
34
16” TNER Chain Container
20” TNER Chain Container
25” TNER Chain Container
32” TNER Chain Container
*See Section 3-2 for necessity and use.
2
1
1
1
1
1
1
1
1
Parts Per
Hoist
1
1
1
1
1
4
4
1
1
2
2
2
1
005L
SA1BL9331
SA1BL9337
ER1BL9332
J1BG10602525
SA1BS1338
SA1BL99801
9091262
SA1BS9962
9091262
9012709
9093420
8330701 (50ft)
8330702 (80ft)
8330703 (110ft)
010L 020L 010S 020S
SA1CL1331
ER1DS9333
ER1CS9334
SA1CL9337
ER1CL9332
J1AP25001212
9009410
J1BG10603535
SA1CS1338
SA1CL99801
901286
9012511
9012709
9093420
9091263
9012711
9093424
SA1CL9962
9091286
9012711
9093424
8330701 (28ft)
8330702 (40ft)
8330701 (14ft.) 8330701 (28ft.) 8330701 (14ft.)
8330702 (20ft) 8330702 (40ft) 8330702 20ft)
8330703 (70ft) 8330703 (35ft) 8330703 (70ft) 8330703 (35ft)
8330704 (100ft) 8330704 (50ft) 8330704 (100ft) 8330704 (50ft)
8330705 (130ft) 8330705 (65ft) 8330705 (130ft) 8330705 (65ft)
8330706 (180ft) 8330706 (90ft) 8330706 (180ft) 8330706 (90ft)
Figure 9-5 Electric Parts
Fig No Part Name
1 Limit Switch Assembly
2 Socket Bolt
3 Spring Washer
4 Plate Assembly
5 Transformer
6 Machine Screw
7 Terminal Plate
8 Mach. Screw w/ Spring Washer
9
Terminal Strip
E-Stop Contactor (Optional)
10
Mach. Screw w/Spring Washer
Machine Screw (for optional Estop contactor)
11 Electromagnetic Contactor
12 Machine Screw
13 Plate Screw
14 Fuse
15 Fuse Holder
16 Mach. Screw w /Spring Washer
17 Mach. Screw w /Spring Washer
18 Lead Wire Assembly
Parts Per
Hoist
1
3
3
2
3
1
1
2
1
1
2
2
1
2
2 (3)
1
1
1
2
1
005L
SA1DHM05L5A2
SA1DHM05L9A23
010L 020L
SA1BS2551
9091247
9012709
SA1DHM10L5A2
TRF62M611
MS555010
ECP1309AD
J1AW24001010
ECP1403AB
MGC14306C
J1AW2-4001010
J1AW2-4001616
MGC23406C
J1AP24001212
ER1BS9445
ECP91FZ06
ECP92FZAA
E2D667125
MS555010
010S 020S
J1BA10601515
SA1DHM10S5A2
SA1CHM10L9A23
*Quantities in “()” are for 010L/S and 020L/S hoists.
Socket Holder
(Standard)
Cable configuration patterns
Figure 9-6 Power Supply and Pendant Parts
Connect to
Gear Case F
(Page 38, No.35)
Holder Plate
(Optional for
Large Diameter
Cable)
Fig No Part Name
1 Socket Holder Assembly
2 Socket Holder 27
3 Holder 13
4 Holder 14
6 Machine Screw w/ Spring Washer
7 Socket Holder Packing
8 Machine Screw w/ Spring Washer
9 Cable Support Arm
40 Power and Control Cable Complete Assembly with Strain Relief (Double Hubbell)
10 Power and Control Cable Complete Assembly with Strain Relief (Double Pigtail)
11 Strain Relief Snap Assembly kit
- Strain Relief Swivel Snap Hook
- Strain Relief Shrink Tubing
- Strain Relief Nylon Strap
- Strain Relief Crimp Ring for Power Cable
- Strain Relief Crimp Ring for Control Cable
13 Power Supply Cable 4C Complete Assembly
14 Power Supply Cable 4C
17 Control Cable 4C Complete Assembly
18 Control Cable 4C
21 Male Hubbell plug for power
22 Female Hubbell plug for control
23 Pendant with Cord and Hubbell Plug Complete Assembly with Emergency Stop
27 Pendant with Cord Complete Assembly with Emergency Stop
24 Pendant Cord
25 Pendant Assembly
26 Warning Tag
22 Female Hubbell plug
28 Pendant with Cord and Hubbell Plug Complete Assembly without Emergency Stop
27 Pendant with Cord Complete Assembly
24 Pendant Cord
25 Pendant Assembly
26 Warning Tag
22 Female Hubbell plug ft
1 ft
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Parts
Per
Hoist
1
1
1
1
2
1
1
1
4
005L 010L 020L
SA1BL1511
SA1BL9511
ECP5913AA
ECP5914AA
J1AP26001212
ER1BS9512
MS561010
SA1BS9541
70954
70955
70956
9015906
9013806
9015905
9009902
9009903
7059395
14/4C
7059495
16/4C
HBL2431
HBL2433
7059095
7059195
16/4C
9012877
WTAG7
HBL2433
8082095
8082195
16/4C
9012877
WTAG7
HBL2433
010S 020S
Fig No Part Name
Parts
Per
Hoist
* Holder Plate Components (Optional for Large Diameter Cable, more than 0.57” up to 0.87”)
31 Cable Packing 1
32 Cable Holder Plate
33 Holder B
34 Holder Packing
35 Holder Nut
36 Holder Cap
37 Holder A
** Single Convertible Cable components (Optional for Single socket)
5 Holder Cap
43 Single Convertible Cable Complete Assembly with Strain Relief (7-pin “Socapex”)
44 Single Convertible Cable Complete Assembly with Strain Relief (14-pin)
16 Single Convertible Cable Complete Assembly with Strain Relief (Single Pigtail)
11 Strain Relief Snap Assembly kit
15 Convertible Cable 7C
*** Compound Cable components (Optional for Double Hubbell Configuration
41 Controller Adapter (Whip) – 7pin “Socapex”
42 Controller Adapter (Whip) – 14pin
21 Male Hubbell plug
22 Female Hubbell plug
2
1
1
1
2
2
1
1
1
1
1
1
1
1
1
005L 010L 020L 010S
Depends on cable diameter – up to 0.87”
SA1CL9511
ECP5924AB
ECP5924AC
ECP5924AD
ECP5924AE
ECP5924AA
ECP5900EA
70951
70952
70953
70956
16/7C
7066395
7066295
HBL2431
HBL2433
020S
Appendix A: Wiring Diagram
53
54
CONTENTS OF EC DECLARATION OF CONFORMITY
Product : TNER Electric Chain Hoist, for use with or without the relevant serial trolleys in capacity range of 1/2 ton up to 2 ton, to which this declaration relates is in conformity with the following EC directives and standards.
The undersigned hereby declares, on behalf of Harrington Hoists, Inc., a legal subsidiary of the KITO
Corporation (of Nakakoma-gun, Yamanashi, Japan), that the above referenced product, to which this declaration relates, is in conformity with the following EC directives and standards.
EC Directives:
Machinery Directive
EMC Directive
Low Voltage Directive
Harmonized Standards:
EN ISO 12100: 2010
EN 14492-2: 2006+A1:2009
EN 818-7: 2002+A1: 2008
EN ISO 13850: 2008
EN 60204-1: 2006
EN 60204-32: 2008
EN 61000-6-4: 2007
EN 61000-6-2: 2005
National Standards:
FEM 9.511: 1986
FEM 9.683: 1995
BGV-D8: 1980
IGVW SQP2: 2013
2006/42/EC
2014/30/EU
2014/35/EU
Risk assessment and risk reduction
Power driven hoists
Short link chain for lifting purposes
Emergency stop
Electrical equipment of machines
Electrical equipment of machines
Electromagnetic compatibility - Emission
Electromagnetic compatibility - Immunity
Classification of mechanisms
Section of lifting and travel motors
Winch, Hoist and pulling device
Chain hoist
55
Harrington Hoists, Inc.
401 West End Avenue
Manheim, PA 17545
www.keg.kitoamericas.com
Toll Free: 800-233-3010
Phone: 717-665-2000
Fax: 717-665-2861
© HARRINGTON HOISTS, INC.
ALL RIGHTS RESERVED
TNEROM-ENG
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